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General Dynamics 7200 - User Manual

General Dynamics 7200
252 pages
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CG-1280
REV N
AUGUST 2013
OPERATION AND MAINTENANCE MANUAL
FOR THE
7200 ANTENNA CONTROL SYSTEM
3750 W. Loop 281
Longview, Texas 75604
EXPORT CONTROL WARNING -
the disclosure of this
document or its contents to non-
U.S. persons, or the
transmission of its contents outside the United States must
be in compliance with U.S. Export Laws and Regulations.
The bearer of this document is under obligation to know the
applicable restrictions for the dissemination of its contents
that relate to U.S. Export Laws and Regulations or any other
U.S. government approvals.

Table of Contents

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General Dynamics 7200 Specifications

General IconGeneral
BrandGeneral Dynamics
Model7200
CategoryControl Systems
LanguageEnglish

Summary

1.0 Introduction

1.1 Purpose

Explains the manual's objective: providing information for installing and operating the General Dynamics SATCOM Technologies 7200 ACS.

1.2 Scope

Details the manual's coverage, focusing on 7200 ACS information and peripheral equipment.

1.3 Organization of Included Contents

Outlines the structure of the manual, detailing each section and appendix.

1.4 Supplemental Literature on CD and Website

Identifies related documentation available on CD and the company website.

1.4 Technical Support

Provides contact information and resources for obtaining technical assistance with the 7200 ACS.

1.5 Important Safety Information

Details critical safety warnings, symbols, and precautions for personnel.

1.5.1 Explanation of Safety Symbols

Explains the meaning of safety symbols used in the manual and on the equipment.

1.5.2 Technical & Environmental Specifications

Lists the technical and environmental specifications for the 7200 ACS unit.

1.5.3 User Supplied Power Cord Requirements

Specifies the requirements for user-supplied power cords for the ACU.

1.5.4 Note about connecting;disconnect from mains power

Provides a note regarding the accessibility of the main power source for disconnection.

2.0 Overview of the 7200 ACS

2.1 General Information About the 7200 ACS

Provides a general overview of the 7200 ACS, its capabilities, and technology.

2.2 System Specifications

Details the performance specifications of the 7200 ACS for various applications.

2.3 System Configuration

Describes the typical block diagram and configuration of the integrated 7200 ACS.

2.4 System Hardware

Identifies the main subsystems comprising the 7200 ACS.

2.4.1 7200 ACU Hardware

Details the technical components and architecture of the 7200 ACU hardware.

2.4.2 Antenna Drive Cabinet Hardware

Describes the hardware components and specifications of the antenna drive cabinet.

2.5 Controls and Indicators

Locates and describes the controls and indicators on the ACU and drive cabinet.

2.5.1 7200 ACU Controls and Indicators

Details the controls and indicators found on the ACU's front and rear panels.

2.5.2 Drive Cabinet Controls and Indicators

Lists and describes the controls and indicators located on the drive cabinet's PMCU and Relay PCB.

2.6 System Functions

Explains the various antenna position control and advanced tracking modes available.

2.7 Standby

Describes the Standby mode, where the ACU waits for instructions without commanding antenna movement.

2.8 Manual Control Via Portable Maintenance Control Unit (PMCU)

Explains manual antenna control using the PMCU, both with and without a display.

2.9 Immediate Tracking

Details methods for quickly initiating tracking for testing or moving antennas to locations.

2.10 Tracking Functions

Lists the available tracking modes for establishing target-specific databases.

3.0 Theory

3.1 OPT

Provides in-depth information on Orbit Prediction Tracking (OPT) capabilities.

3.1.1 Orbit Prediction

Explains the algorithm used by the 7200 ACS to predict spacecraft position using propagators.

3.1.2 Orbit Determination

Describes how orbital element sets are refined using AST data and propagators for accurate tracking.

3.2 Orbit Scan

Details the Orbit Scan algorithm for locating satellites in inclined orbits.

3.2.1 Orbit Scan Theory

Explains the theory behind the Orbit Scan method for geosynchronous satellites in inclined operation.

4.0 Installation and Initial Setup of System

4.1 Overview

Introduces the section on system installation and initial setup, including connection details.

4.2 Mechanical Installation

Covers the mechanical aspects of installation, including component mounting.

4.2.1 Antenna-Mounted Components

Details mechanical interfaces for antenna-mounted components and their installation.

4.2.2 Installing the Drive Cabinet

Provides procedures for locating, grounding, and attaching the drive cabinet to the foundation.

4.2.3 Installing the 7200 ACU

Explains the process of mounting the 7200 ACU into a rack-mounted slide assembly.

4.3 System Cabling

Describes the cabling requirements for connecting the 7200 ACS components.

4.3.1 Drive Cabinet Main Power Connection

Details the procedure for connecting the main power to the drive cabinet.

4.3.2 Connecting the Drive Motors to the Drive Cabinet

Provides motor connection procedures for AZ, EL, and POL motors to the drive cabinet.

4.3.3 Limit Switch Connections

Explains how to connect limit switches to TB1 terminals on the drive cabinet.

4.3.4 Installing the 7200 ACU Control Cable

Describes the installation procedures for the 7200 ACU control cable.

4.3.4.1 Standard System 7200 ACU Control Cable Installation

Details the connection of the 25-conductor cable to the ACU and drive cabinet.

4.3.5 Resolver and Encoder Connections

Explains how to connect resolvers and encoders for position feedback.

4.3.5.1 Resolver Connections

Provides connection details for size-11 resolvers to ACU rear panel connectors.

4.3.6 Analog Input Connections

Details the analog input port connection via J21 for tracking signal input.

4.3.7 Digital Inputs

Shows the input pairs for the Digital Input, J11, on the 7200 ACU.

4.3.8 Remote Communications Connections

Lists connections for remote communication ports, including EIA/TIA-232E, EIA/TIA-422B, and Ethernet.

4.3.9 Remote Beacon Select and Summary Fault Connections

Describes connections for summary fault output and remote beacon selection to TB1.

4.4 Initial Power-Up and System Setup

Outlines the procedures for system power-up and initial configuration.

4.4.1 Drive Cabinet Power-Up and Initialization

Details the initial power-up and setup steps for the drive cabinet's modules.

4.4.1.3 Drive Motor Phasing

Explains procedures to ensure correct direction of antenna axis rotation relative to commands.

4.4.1.4 Electrical Limit Switch Tests and Preliminary Settings

Describes how to test electrical limit switches and set preliminary parameters.

4.4.2 ACU Power-Up and Initialization

Covers the procedures to prepare the system for site acceptance tests.

4.4.2.1 Setting Position Parameters

Guides on setting position parameters, including transducer direction and station location.

4.4.2.2 Setting Beacon Signal Level and Slope

Details the process for calibrating the tracking signal by setting beacon level and slope.

5.0 Operation

5.1 Introduction

Introduces operational procedures, the menu system, and the help system.

5.2 The 7200 ACS Menu System

Explains how to navigate and use the 7200 ACS menu system for accessing capabilities.

5.2.1 Multiscreen Menus

Describes how to view and navigate through multiscreen menus.

5.2.2 Menu Items

Explains how menu items and parameters vary based on system conditions.

5.3 The Help System

Details how to access and use the context-sensitive on-line help system.

5.4 System Prompts

Explains how system prompts simplify executing functions and changing parameters.

5.4.1 Error Messages for Incorrect Entries

Describes how the system provides error messages for out-of-range value entries.

5.6 Power-Up Procedures

Outlines the procedures for powering up the 7200 ACS system.

5.7 Manual Movement of the Antenna

Provides instructions for manually controlling antenna movement.

5.7.1 Manual Movement From the Drive Cabinet (PMCU)

Details manual antenna control from the drive cabinet using the PMCU.

5.7.2 Manual Movement From the ACU

Explains how to manually control the antenna from the ACU.

5.8 The 7200 ACS Main Menu

Describes how all 7200 ACS operation is accessed through the Main Menu.

5.8.1 Return to Standby (Stop Tracking) Function

Explains how to place the system in Standby mode, stopping antenna movement.

5.8.2 Tracking Functions Menu

Details access to antenna control, including manual control and tracking functions.

5.8.2.2 Track a Target Menu

Allows selection of a preconfigured target for tracking.

5.8.2.3 Modify Current Target Menu

Enables modification of the currently tracked target's parameters.

5.8.2.3.1 Manually Bias Target Function

Allows users to create a bias for a target, used for calibrating polarization.

5.8.2.4 Immediate Tracking Menu

Enables users to begin tracking without prior target configuration.

5.8.2.4.1 Steptrack Parameters

Describes steptracking parameters and their default settings for system operation.

5.8.2.5 Manual Antenna Control Function

Explains how to manually control antenna movement using Momentary and Sticky modes.

5.8.2.6 Edit a New or Existing Target Menu

Allows configuration of up to 50 targets for the target-oriented environment.

5.8.2.6.1 Target Name Parameter

Details how to name or edit target names, with a limit of 12 characters.

5.8.2.6.2 Tracking Mode Parameter

Guides users on changing the tracking mode for a target.

5.8.2.6.3 Edit Target Parameters Menu

Allows editing of parameters specific to the selected tracking mode.

5.8.2.6.3.1 Star Tracking Mode Parameters

Describes parameters for Star tracking, including preset stars and user-definable entries.

5.8.2.6.3.2 OPT Tracking Mode Parameters

Details parameters specific to the OPT tracking mode.

5.8.2.6.3.3 Intelsat 11-Element Tracking Mode Parameters

Lists parameters for Intelsat 11-Element (IESS-412) tracking mode.

5.8.2.6.3.6 Orbital Element Tracking (OPTIONAL)

Describes parameters for the Orbital Element Tracking (OET) mode.

5.8.2.7 Target Scheduler Menu

Allows programming up to 200 targets with specific tracking dates and times.

5.8.3 Clear;Correct System Faults Function

Details clearing system faults, acknowledging uncorrectable faults, and managing alarms.

5.8.4 Set User Level (and Passwords) Menu

Covers setting user levels (Monitor, Operator, Supervisor) and managing passwords.

5.8.5 Display System Status Menu

Provides access to various system status displays for diagnostics.

5.8.5.1 Hardware Diagnostics

Explains hardware diagnostics, including input/output states and A/D states.

5.8.5.2 Position Loop Diagnostics

Shows the real-time states of the position loop task and Finite State Machine (FSM) for each axis.

5.8.5.3 Steptrack Statistics

Provides real-time information on steptrack operations and final values.

5.8.5.4 OPT Statistics

Displays useful OPT statistics intended for use by General Dynamics personnel.

5.8.5.5 Orbit Data

Provides information from current target OPT solutions, useful for setting Box limits.

5.8.5.6 Box Limits

Details the limits in use and current pointing location, assisting in troubleshooting Box limit errors.

5.8.5.7 Background Tasks

Indicates whether background tasks are awake or asleep.

5.8.5.8 Simulated Target

Shows simulated target position and error, useful in SIMULATION mode.

5.8.5.9 Star Viewing Windows

Displays visibility windows for stars, used for G/T testing.

5.8.5.11 Serial Diagnostics Menus

Displays raw status values from tracking receivers for serial link troubleshooting.

5.8.5.12 Power-up Test Report

Shows the time of last ACU power-up and any detected I/O card errors.

5.8.5.13 Firmware Version Information

Provides ACU firmware version details, including configuration and build information.

5.8.6 Edit System Configuration Menu

Allows viewing and modifying system configuration parameters.

5.8.6.1 Tracking Receiver Parameters Menu

Details parameters for tracking receiver setup based on the selected shell.

5.8.6.2 Tracking Receiver Setup Menu

Used to configure the tracking receiver before Steptrack or OPT.

5.8.6.4 Position Encoder Configuration Menu

Allows setting position encoder offsets and direction.

5.8.6.5 Motion Limits Menu

Defines software and motion error limits to ensure safe antenna movement.

5.8.6.5.1 Soft Limits

Explains software travel limits that prevent driving the antenna beyond safe operational ranges.

5.8.6.5.3 Immobile and Reversed Errors

Covers parameters governing immobile and reversed axis errors.

5.8.6.5.4 Runaway Errors

Explains the cause and correction for axis runaway errors.

5.8.6.6 Position Loop Parameters

Controls how the antenna moves to the target and the precision of its position.

5.8.6.7 Built-in Simulator Setup

Allows configuration of the simulator for training or M&C interface testing.

5.8.6.8 Set UTC Date and Time

Provides procedures for setting the system clock to UTC for accurate tracking.

5.8.6.9 Site Data

Enables input of site-specific data like antenna name, latitude, and longitude.

5.8.6.10 RF;Geometry

Enables/disables POL control and sets RF/geometry correction parameters.

5.8.6.11 Network Configuration

Sets communications and protocol parameters for network ports.

5.8.6.11.2 IP Address

Details the configuration of the unique IP address for network identification.

5.8.6.11.3 Subnet Mask

Explains the use of subnet masks for determining network data routing.

5.8.6.11.4 Gateway Address

Specifies the IP address of a router for non-local network communication.

5.8.6.12 Remote Port Configuration

Controls remote communications via serial ports, defining shells and parameters.

5.8.6.13 ACU Sync Configuration (OPTIONAL)

Configures synchronization behavior for systems with redundant ACUs.

5.8.6.14 User Interface Options Menu

Allows configuration of display settings, alarms, and security features.

5.8.6.15 Tracking Restoration Options Menu

Controls how the ACU restores tracking after interruptions like power loss or faults.

5.8.6.16 Factory Tests

Provides tests used at the factory, also useful for field troubleshooting.

5.8.6.16.3 Reset ACU to ROM Defaults

Resets all parameters to ROM defaults, erasing targets and steptrack data.

5.8.6.17 Message Printer Options

Allows selective inclusion/exclusion of messages for the optional message printer.

6.0 Maintenance

6.1 Air Filter

Details the procedure for cleaning or replacing the ACU's air filter.

6.2 Battery

Provides information on monitoring and replacing the VCPU battery.

6.2.1 Checking the Battery

Explains how to check the battery charge and its impact on NVRAM parameters.

6.2.2 Replacing the Battery

Outlines the procedure for replacing the battery without losing parameters.

6.3 Power Entry Module Fuse

Specifies the fuse type and rating required for the ACU's power entry module.

7.0 Engineering Drawings

APPENDIX A - ACRONYMS AND ABBREVIATIONS

APPENDIX B - 7200 ACU PASSWORD PROTECTION

APPENDIX C - TWO-SPEED RESOLVER CALIBRATION

1.0 Introduction

Introduces instructions for calibrating two-speed resolvers in the 7200 ACS.

2.0 Setting Excitation Voltage

Details how to check and set the resolver excitation voltage for stability.

3.0 Two-Speed Internal Alignment

Explains the procedure to align coarse and fine resolver 0 points for accurate positioning.

APPENDIX D - TRACKING TUTORIAL

1.0 Introduction

Provides information for quickly setting up tracking with the 7200 ACS.

APPENDIX E - 7200 Troubleshooting Guide

1.0 Drive Cabinet Unresponsive;Inverter Display Blank

Troubleshooting steps for a drive cabinet that does not respond or has a blank inverter display.

2.0 Drive Cabinet Inverter Faults

Lists faults indicated by AZ|EL FLT on the ACU and refers to inverter parameter setup.

2.1 Overcurrent [oC]

Details causes and troubleshooting for overcurrent errors indicated by [OC] on the inverter.

2.2 Overvoltage [oV]

Explains causes and correction for overvoltage errors indicated by [oV] on the inverter.

2.3 Undervoltage [Uv]

Details causes and troubleshooting for undervoltage errors indicated by [Uv] on the inverter.

2.4 Overheating [oH]

Explains causes and checks for overheating errors indicated by [oH] on the inverter.

2.6 Motor Overload [oL1]

Troubleshooting for motor overload detection indicated by [oL1] on the inverter.

3.0 7200 ACU Power-Up Failures

Covers issues related to ACU power-up, including no audible beep and display problems.

4.0 Soft and Hard Travel Limits

Addresses errors related to exceeding operational or mechanical travel limits.

5.0 Resolver Errors

Details troubleshooting steps for resolver errors, including cable checks and resistance readings.

6.0 7200 ACU Error Messages

Lists common ACU error messages, their descriptions, and corrective actions.

6.1 Axis Immobile

Troubleshooting steps for axis immobile errors, checking parameters and connections.

6.2 Axis Reversed

Identifies causes for axis reversed errors, such as motor phasing or miswired encoders.

6.3 Axis Runaway

Troubleshooting steps for axis runaway errors, checking parameters and encoder failures.

7.0 Position Loop Errors

Addresses issues related to position loop errors, such as overshooting.

8.0 Target Acquisition Errors

Lists potential causes for errors occurring during target acquisition.

9.0 AST;OPT Tracking Errors

Covers errors related to AST/OPT tracking, including target setup and signal issues.

10.0 Intelsat (IESS-412) Tracking Errors

Details errors specific to Intelsat 11-Element tracking.

11.0 Password Lost

Procedure for clearing a lost password and entering a new one.

APPENDIX F - SITE TEST PROCEDURE

1.0 SITE ACCEPTANCE TEST PROCEDURE

Provides the final proof of performance document for the 7200 ACS.

1.2 Drive Cabinet Line Voltage Measurements and Power-Up

Details measuring line voltages and performing power-up checks on the drive cabinet.

1.3 Motor Phasing Tests

Tests to verify correct motor phasing for Azimuth, Elevation, and Polarization axes.

1.4 Miscellaneous Error and Fault Messages

Tests various error and fault messages related to drive cabinet and ACU status.

1.5 Limit Switch Tests

Checks the function and setting of electrical limit switches on the antenna structure.

1.6 Manual Antenna Control Tests

Verifies proper operation of manual antenna controls via the ACU keypad.

1.7 Software Limit Tests

Tests the function and setting of soft limits by driving the antenna.

1.8 Steptrack Tests

Evaluates tracking accuracy based on input signal stability and steptrack parameters.

1.8.1 Input Signal Variation

Assesses the stability of the reference tracking signal before evaluating tracking accuracy.

1.8.2 Tracking Accuracy

Guides on recording steptrack defaults and calculating RMS tracking accuracy.

1.8.3 Orbit Prediction Tracking (OPT)

Covers configuring and executing an OPT target based on simulated satellite data.

1.9 System Parameter Recording

Provides tables for recording system parameters during site testing.

APPENDIX G - GRAPHICAL MENU TREE

APPENDIX H - VENDOR DATA

Appendix J FIELD PROCEDURE(s) TO INSTALL CTB055

STANDARD METHOD

Provides standard steps for installing CTB055, including soldering and crimping.

ALTERNATE METHOD IF CTB055 IS NOT AVAILABLE

Details an alternative installation method using heat shrink if CTB055 is unavailable.

Appendix K NORAD Tracking

Element set Format

Describes the format of NORAD two-line element sets for satellite tracking.

Appendix L CP;LP PATH Option Notes

Changes to user interface

Details changes in the real-time display format for feed switch statuses.

Status examples

Provides examples of status indications for CP/LP and PATH states.